Print

Please login or register.
1 Hour 1 Day 1 Week 1 Month Forever
Login with username, password and session length

[domingo3]

Anyone know anything about the "check engine" light?  Apparently this is a new "feature" for 2018 model years.  The manual says: "Indicates the motorcycle has detected an error, causing it to
enter into a state of permanent torque reduction. This light will be accompanied by a dash error code."

The only error codes I saw were 25, 45, 48, and 49.  This is when the bike was turned off and kickstand down.  When I turned it back on, it error code went to 0000, which I assume means no error code.

After a couple of trips, the check engine light is now out.  Do I take it to the dealer or no?  I like riding my bike more than it being at the dealer.

[JaimeC]

Probably something emissions-related. 

[skyvandreren]

This probobly doesn't help but I have noticed the check engine light has come on with my 2018 Zero FX with no error code a few times. I don't know why. Last time it went away after turning the ignition on and off a few times and i has not come back again.

[DPsSRnSD]

Is it anything like the old "System Warning Indicator"? I get it for brief periods of time when I ride through canyons cold enough to cause condensation.

[domingo3]

This probobly doesn't help but I have noticed the check engine light has come on with my 2018 Zero FX with no error code a few times. I don't know why. Last time it went away after turning the ignition on and off a few times and i has not come back again.

It is helpful to hear that nothing more came of it for you.

[domingo3]

I got the check engine light again.  In the logs, it says "Malfunction Indicator (Engine light) turned on because of sevcon cap voltage low and contactor closed"

Can anyone shed some light on what this means?  This is the second time I've gotten it.  It goes away after a couple of rides, but while it's on, I can barely keep up with traffic on the highway.

Code: [Select]

07601                       0   Power On                   Key Switch
 07602                       0   Key On
 07603                       0   DEBUG: Module scheme changed from None mode to Running mode
 07604                       0   Module 00 Opening Contactor  vmod:   0.000V, batt curr:   0A
 07605                       0   Module 01 Opening Contactor  vmod:   0.000V, batt curr:   0A
 07606                       0   Turning ON DCDC
 07607                       0   DEBUG: Module scheme changed from Running mode to Stopped mode
 07608                       1   Module 00 CAN Link Up
 07609                       1   Module 00 Registered       serial: 18gb0452,  vmod: 103.397V
 07610     02/02/2019 12:15:05   Sevcon Turned On
 07611     02/02/2019 12:15:06   Sevcon CAN Link Up
 07612     02/02/2019 12:15:06   DEBUG: Sevcon Contactor Drive ON.
 07613     02/02/2019 12:15:06   Module 00 Closing Contactor  vmod: 103.602V, maxsys: 103.602V, minsys: 103.602V, diff: 0.000V, vcap: 92.312V, prechg: 89%
 07614     02/02/2019 12:15:07   DEBUG: Module 00 Contactor is now Closed
 07615     02/02/2019 12:15:07   INFO:  Enabling External Chg 0 Charger 2
 07616     02/02/2019 12:15:07   INFO:  Enabling External Chg 1 Charger 3
 07617     02/02/2019 12:15:14   Disarmed                   PackTemp: h 254C, l 254C, PackSOC: 57%, Vpack:103.363V, MotAmps:   0, BattAmps:   1, Mods: 01, MotTemp:  10C, CtrlTemp:  -1C, AmbTemp:  -7C, MotRPM:   0, Odo: 3865km
 07618     02/02/2019 12:16:14   Disarmed                   PackTemp: h 255C, l 254C, PackSOC: 57%, Vpack:103.297V, MotAmps:   0, BattAmps:   1, Mods: 01, MotTemp:  10C, CtrlTemp:  -1C, AmbTemp:  -6C, MotRPM:   0, Odo: 3865km
 07619     02/02/2019 12:17:02   DEBUG: Module scheme changed from Stopped mode to Running mode
 07620     02/02/2019 12:17:02   DEBUG: Module mode Change Does Not Require Disconnect
 07621     02/02/2019 12:17:13   Riding                     PackTemp: h 255C, l 254C, PackSOC: 57%, Vpack:103.234V, MotAmps:   0, BattAmps:   1, Mods: 10, MotTemp:   8C, CtrlTemp:  -1C, AmbTemp:  -6C, MotRPM:   0, Odo: 3865km
 07622     02/02/2019 12:18:14   Riding                     PackTemp: h 255C, l 254C, PackSOC: 57%, Vpack:100.503V, MotAmps:  49, BattAmps:  25, Mods: 10, MotTemp:  10C, CtrlTemp:   1C, AmbTemp:  -5C, MotRPM:1412, Odo: 3866km
 07623     02/02/2019 12:19:14   Riding                     PackTemp: h 255C, l 254C, PackSOC: 57%, Vpack:102.114V, MotAmps:   0, BattAmps:   1, Mods: 10, MotTemp:  15C, CtrlTemp:   1C, AmbTemp:  -4C, MotRPM:   0, Odo: 3866km
 07624     02/02/2019 12:20:14   Riding                     PackTemp: h 255C, l 255C, PackSOC: 57%, Vpack:102.202V, MotAmps:   0, BattAmps:   1, Mods: 10, MotTemp:  16C, CtrlTemp:   2C, AmbTemp:  -4C, MotRPM: 356, Odo: 3866km
 07625     02/02/2019 12:21:14   Riding                     PackTemp: h 255C, l 255C, PackSOC: 57%, Vpack:101.858V, MotAmps:   0, BattAmps:   0, Mods: 10, MotTemp:  18C, CtrlTemp:   4C, AmbTemp:  -3C, MotRPM:2387, Odo: 3867km
 07626     02/02/2019 12:21:45   Malfunction Indicator (Engine light) turned on because of sevcon cap voltage low and contactor closed
 07627     02/02/2019 12:21:45   SEVCON CAN EMCY Frame      Error Code: 0x3100, Error Reg: 0x05, Sevcon Error Code: 0x45C3, Data: 04 04 00 D0 01, Unknown
 07628     02/02/2019 12:21:45   SEVCON CAN EMCY Frame      Error Code: 0x0000, Error Reg: 0x01, Sevcon Error Code: 0x45C3, Data: CE 45 00 00 01, Unknown
 07629     02/02/2019 12:21:46   SEVCON CAN EMCY Frame      Error Code: 0x3100, Error Reg: 0x05, Sevcon Error Code: 0x45C3, Data: 04 04 00 07 01, Unknown
 07630     02/02/2019 12:21:46   SEVCON CAN EMCY Frame      Error Code: 0x0000, Error Reg: 0x01, Sevcon Error Code: 0x45C3, Data: CE 45 23 07 01, Unknown
 07631     02/02/2019 12:21:46   SEVCON CAN EMCY Frame      Error Code: 0x3100, Error Reg: 0x05, Sevcon Error Code: 0x45C3, Data: 04 04 00 07 01, Unknown
 07632     02/02/2019 12:21:46   SEVCON CAN EMCY Frame      Error Code: 0x0000, Error Reg: 0x01, Sevcon Error Code: 0x45C3, Data: CE 45 7B D0 01, Unknown
 07633     02/02/2019 12:21:46   SEVCON CAN EMCY Frame      Error Code: 0x3100, Error Reg: 0x05, Sevcon Error Code: 0x45C3, Data: 04 04 00 D0 01, Unknown
 07634     02/02/2019 12:21:46   SEVCON CAN EMCY Frame      Error Code: 0x0000, Error Reg: 0x01, Sevcon Error Code: 0x45C3, Data: CE 45 F0 48 01, Unknown
 07635     02/02/2019 12:21:46   SEVCON CAN EMCY Frame      Error Code: 0x3100, Error Reg: 0x05, Sevcon Error Code: 0x45C3, Data: 04 04 00 55 01, Unknown
 07636     02/02/2019 12:21:46   SEVCON CAN EMCY Frame      Error Code: 0x0000, Error Reg: 0x01, Sevcon Error Code: 0x45C3, Data: CE 45 3E 09 01, Unknown
 07637     02/02/2019 12:21:46   SEVCON CAN EMCY Frame      Error Code: 0x3100, Error Reg: 0x05, Sevcon Error Code: 0x45C3, Data: 04 04 00 2B 01, Unknown
 07638     02/02/2019 12:21:46   SEVCON CAN EMCY Frame      Error Code: 0x0000, Error Reg: 0x01, Sevcon Error Code: 0x45C3, Data: CE 45 36 10 01, Unknown
 07639     02/02/2019 12:22:14   Riding                     PackTemp: h 0C, l 255C, PackSOC: 56%, Vpack: 95.711V, MotAmps:  28, BattAmps:  38, Mods: 10, MotTemp:  20C, CtrlTemp:   5C, AmbTemp:  -2C, MotRPM:4041, Odo: 3868km
 07640     02/02/2019 12:23:14   Riding                     PackTemp: h 1C, l 0C, PackSOC: 55%, Vpack: 92.396V, MotAmps:  51, BattAmps:  69, Mods: 10, MotTemp:  26C, CtrlTemp:   7C, AmbTemp:  -1C, MotRPM:3849, Odo: 3870km
 07641     02/02/2019 12:24:14   Riding                     PackTemp: h 2C, l 2C, PackSOC: 55%, Vpack: 95.483V, MotAmps:  60, BattAmps:  46, Mods: 10, MotTemp:  28C, CtrlTemp:   7C, AmbTemp:  -1C, MotRPM:2226, Odo: 3871km
 07642     02/02/2019 12:25:14   Riding                     PackTemp: h 3C, l 2C, PackSOC: 56%, Vpack: 99.872V, MotAmps:  42, BattAmps:   7, Mods: 10, MotTemp:  29C, CtrlTemp:   7C, AmbTemp:  -2C, MotRPM: 453, Odo: 3872km
 07643     02/02/2019 12:26:14   Riding                     PackTemp: h 4C, l 3C, PackSOC: 56%, Vpack:101.001V, MotAmps:   0, BattAmps:   1, Mods: 10, MotTemp:  28C, CtrlTemp:   7C, AmbTemp:  -1C, MotRPM:  59, Odo: 3872km
 07644     02/02/2019 12:26:43   Throttle Disabled:         Kickstand Sw,
 07645     02/02/2019 12:26:44   DEBUG: Module scheme changed from Running mode to Stopped mode
 07646     02/02/2019 12:26:44   DEBUG: Module mode Change Does Not Require Disconnect
 07647     02/02/2019 12:26:46   Power Off                  Key Switch
 07648     02/02/2019 12:26:46   Sevcon Turned Off
 07649     02/02/2019 12:26:46   Module 00 Opening Contactor  vmod: 101.131V, batt curr:   1A
 07650     02/02/2019 12:26:46   Module 01 Opening Contactor  vmod:   0.000V, batt curr:   0A
 07651     02/02/2019 12:26:46   INFO:  Disabling External Chg 0 Charger 2
 07652     02/02/2019 12:26:47   INFO:  Disabling External Chg 1 Charger 3
 07653     02/02/2019 12:26:47   Turning OFF DCDC. Flags: 0x00


[NoMoreIdeas]

I have had the exact same error code, finally took some time to read into it a couple of days ago since the engine light has popped on ~3 times now. I've noticed it when its fairly cold outside and i'm less than ~70% charged, and get on the throttle. It seems to go away after I cycle the key a couple of times, but as long as its cold it comes back. Kinda wondering if it has to do with voltage sag when its cold? 18FX by the way. Today it was 60f and I've had it out for a few hours with a heavy throttle hand, no check engine light!

[BrianTRice@gmail.com]

Have your dealer check the logs out, and then the bike. Your controller may actually be malfunctioning and if so, it's in your interest to have them replace it under warranty before it becomes a damaging problem.

[BrianTRice@gmail.com]

And there is nothing about this light that is new; it's behaved the same since the introduction of the Zero-specific dash in 2014.

[DonTom]

Probably something emissions-related. 

My Tesla has an emissions mode. When activated, the car will fart from the seat of my choice (really, not BS).

-Don- Auburn, CA

[domingo3]

And there is nothing about this light that is new; it's behaved the same since the introduction of the Zero-specific dash in 2014.

I understand that the dash was not re-designed in 2018, but I don't think the check engine light was functional 2017 and earlier.  The 2018 manuals describe the check engine light on page 3.11.  The 2017 manuals do not and I have not heard or read any reports of the light being on the earlier models. 

You're probably right that I should have the dealer check it out.  I just hate taking the bike in to the dealer because I ride every day and my past experience is that the process takes me off of the bike for way too long.

[BrianTRice@gmail.com]

Oh, right. The system warning indicator is a vague proxy for this on earlier models like mine.

Basically, one just learns to check for error codes when the system warning light comes on.

And (side note) most "error codes" are normal, as you noticed, and (IMO) should be referred to as "condition codes", because you have to think through the state of the bike to work out whether a good number of them indicate problems or not.


I do understand the hesitance to leave the bike with the dealer on a number of levels. Hopefully you can get a loaner vehicle if it requires significant work or parts shipments.

[Curt]

Internetz research: apparently there are some big capacitors connected to the motor and they need to pre-charge through some resistors so that by the time the contactor closes, their voltage is similar to the battery voltage. Sevcon 0x45c3 indicates the capacitors had not charged enough by the time the contactor closed. That would cause a current spike. I wonder if this issue is what has been frying contactors?

[Auriga]

I would try pulling the bike and battery logs and sending them to Zero, then calling and asking them to review it. I did that for a recent issue that turned out to be inconsequential, and I saved a trip to the dealer.

[BrianTRice@gmail.com]

Internetz research: apparently there are some big capacitors connected to the motor and they need to pre-charge through some resistors so that by the time the contactor closes, their voltage is similar to the battery voltage. Sevcon 0x45c3 indicates the capacitors had not charged enough by the time the contactor closed. That would cause a current spike. I wonder if this issue is what has been frying contactors?

That's the precharge function that the BMS performs, described here:
https://zeromanual.com/wiki/Precharge_Theory

The BMS has its own checks for deciding whether to close the contactor based on whether precharge has raised voltage to a sufficient level (compared to battery terminal voltage).

Usually, if precharge fails, keying the bike off and on for an interval of a few seconds allows a second precharge cycle to be performed without much capacitor decay in between, thus resulting in a boost.

The contactor itself has been a robust part of the Zero platform since 2014, to my understanding. But yes it can wear out in principle if enough current rush happens.

A controller degradation might explain all of this, and is my preferred hypothesis right now, though I'm just some frood on the internet - definitely have a technician look at it and perform some live diagnostics if there isn't direct evidence.